Polymer blend of carbon monoxide/olefin copolymer and poly(arylsulfone)oligomer

ABSTRACT

Blends of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon and a poly(arylsulfone) oligomer show improved processability as compared with the unblended polymer.

This application is a continuation-in-part of copending U.S. patent application Ser. No. 203,958 filed June 8, 1988, U.S. Pat. No. 4,839,435.

FIELD OF THE INVENTION

This invention relates to improved blends comprising a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon and other polymeric material. More particularly, the invention relates to blends of the linear alternating polymer and a low molecular weight poly(arylsulfone) polymer.

BACKGROUND OF THE INVENTION

The class of polymers of carbon monoxide and olefin(s) has been known for a number of years. Brubaker, U.S. Pat. No. 2,495,286, produced such polymers of relatively low carbon monoxide content in the presence of free radical initiators, e.g., peroxy compounds. U.K. Pat. No. 1,081,304 produced similar polymers of higher carbon monoxide content in the presence of alkylphosphine complexes of palladium salts as catalyst. Nozaki extended the process to produce linear alternating polymers through the use of arylphosphine complexes of palladium moieties and certain inert solvents. See, for example, U.S. Pat. No. 3,694,412.

More recently, the class of linear alternating polymers of carbon monoxide and at least one ethylenically unsaturated hydrocarbon has become of greater interest in part because of the greater availability of polymers. Such polymers, for example copolymers of carbon monoxide and ethylene or terpolymers of carbon monoxide, ethylene and propylene, are often referred to as polyketones or polyketone polymers and have been shown to be of the repeating formula --CO--A-- where A is the moiety of unsaturated hydrocarbon polymerized through the ethylenic unsaturation. By way of illustration, when the unsaturated hydrocarbon is ethylene, the polymers are represented by the repeating formula --CO--CH₂ --CH₂ --. The general process for the production of such polymers is illustrated by a number of published European Patent Applications including Nos. 121,965, 181,014, 222,454 and 257,663. The process generally involves the use of a catalyst composition formed from a compound of palladium, cobalt or nickel, the anion of a non-hydrohalogenic acid having a pKa below 2 and a bidentate ligand of phosphorus, arsenic or antimony.

The resulting polyketone polymers are relatively high molecular weight thermoplastics having established utility in the production by conventional procedures of shaped articles such as containers for food and drink and shaped parts for the automotive industry. For some particular applications it has been shown to be desirable to have properties which are somewhat different from those of the polyketone polymer. It would be of advantage to retain the desirable properties of the polyketone polymer and yet improve other properties. These advantages are often obtained through the provision of a polymer blend.

SUMMARY OF THE INVENTION

This invention relates to blends of linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon with other polymeric material. More particularly, there is provided according to the invention, blends of the linear alternating polymer and low molecular weight poly(arylsulfone) polymer. These blends demonstrate an improved processability as compared with the linear alternating polymer or with a blend of the linear alternating polymer with poly(arylsulfone) polymer of higher molecular weight.

DESCRIPTION OF THE INVENTION

The polyketone polymers which are employed as the major component in the blends of the invention are linear alternating polymers of carbon monoxide and at least one ethylenically unsaturated hydrocarbon. Suitable ethylenically unsaturated hydrocarbons for use as precursors of the polyketone polymers have up to 20 carbon atoms inclusive, preferably up to 10 carbon atoms inclusive, and are aliphatic such as ethylene and other α-olefins including propylene, 1-butene, isobutylene, 1-octene and 1-dodecene, or are arylaliphatic having an aryl substituent on an otherwise aliphatic molecule, particularly an aryl substituent on a carbon atom of the ethylenic unsaturation. Illustrative of this latter class of ethylenically unsaturated hydrocarbons are styrene, p-methylstyrene, p-ethylstyrene and m-methylstyrene. Preferred polyketone polymers are copolymers of carbon monoxide and ethylene or terpolymers of carbon monoxide, ethylene and a second hydrocarbon of at least 3 carbon atoms, particularly an α-olefin such as propylene.

The structure of the polyketone polymer is that of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon and the polymer will contain substantially one molecule of carbon monoxide for each molecule of hydrocarbon. When terpolymers of carbon monoxide, ethylene and a second hydrocarbon are employed in the blends of the invention, there will be within the polyketone polymer at least about 2 units incorporating a moiety of ethylene for each unit incorporating a moiety of the second hydrocarbon. Preferably, there will be from about 10 units to about 100 units incorporating a moiety of ethylene for each unit incorporating a moiety of the second hydrocarbon. The polymer chain is therefore represented by the repeating formula

    --CO--CH.sub.2 --CH.sub.2)].sub.x [CO--B)].sub.y           (I)

where B is the moiety obtained by polymerization of the second hydrocarbon through the ethylenic unsaturation. The --CO--CH₂ --CH₂ -- units and the --CO--B-- units are formed randomly throughout the polymer chain and the ratio of y:x is no more than about 0.5. In the modification where copolymer of carbon monoxide and ethylene is employed, the second hydrocarbon is not present in the polymer chain and the copolymer is represented by the above formula (I) wherein y is 0. When y is other than 0, i.e., a terpolymer is employed, ratios of y:x from about 0.01 to about 0.1 are preferred. The end groups or "caps" of the polymer chain will depend upon what materials are present during the production of the polymer and whether and how the polymer has been purified. The precise nature of the end groups is of little importance so far as the overall properties of the polymer are concerned, however, and the polyketone polymer is fairly represented by the above formula. Of particular interest are the polymers of the above formula (I) of number average molecular weight from about 1000 to about 200,000, more particularly those of a number average molecular weight from about 20,000 to about 90,000, as determined by gel permeating chromatography (GPC). The physical properties of the polymers will depend in part on the molecular weight of the polymer, whether the polymer is a copolymer or a terpolymer and the relative proportion of the second hydrocarbon in the case of terpolymers. Typical melting points for such polymers are from about 175° C. to about 300° C., more often from about 210° C. to about 270° C.

A method of producing the polyketone polymers which is now becoming conventional is to contact the carbon monoxide and hydrocarbon(s) with a catalyst composition formed from a palladium compound, an anion of a non-hydrohalogenic acid having a pKa below about 6, preferably below 2, and a bidentate ligand of phosphorous. Such a process for polyketone production is illustrated by the above published European Patent Applications. The scope of the polymerization is extensive, but without wishing to be limited, a preferred palladium compound is a palladium carboxylate, particularly palladium acetate, the preferred anion is the anion of trifluoroacetic acid or p-toluenesulfonic acid and the preferred bidentate, phosphorus ligand is 1,3-bis(diphenylphosphino)propane or 1,3-bis[di(2-methoxyphenyl)phosphino]propane.

Polymerization is conducted under polymerization conditions in the gaseous phase or in a liquid phase in the presence of a reaction diluent, e.g., a lower alkanol such as methanol or ethanol. The reactants are contacted by conventional methods such as shaking or stirring. Suitable reaction temperatures are from about 20° C. to about 150° C. with preferred temperatures being from about 50° C. to about 135° C. Typical reaction pressures are from about 1 bar to about 200 bar, more typically from 10 bar to about 100 bar. Subsequent to reaction the polymer product is recovered as by filtration or decantation. The polyketone polymer may contain residues of the catalyst composition which are removed, if desired, by treatment of the polymer product with a solvent or a complexing agent which is selective for the catalyst residues.

The poly(arylsulfone) polymer employed as the minor component of the blends of the invention is a low molecular weight polymer, also referred to as an oligomer, wherein the repeating unit is a polyaryl sulfone moiety in which the aryl portion comprises at least two arylene, particularly phenylene, rings which are directly connected or are joined by an oxygen, sulfur, oxygen or alkylidine connecting group or mixtures of such connected ring systems. These poly(arylsulfone) oligomers are broadly known in the art and are represented by the formula ##STR1## where Z independently is a direct carbon-carbon bond between the indicated phenylene rings, oxygen, sulfur or 2,2-propylidine, and n is an average number of from about 3 to about 20 inclusive. While the relative substitution on the phenylene rings is suitably ortho, meta or para, the preferred poly(arylsulfone) oligomers contain phenylene moieties wherein the connecting groups are entirely para to the other group on the same phenylene ring. The preferred poly(arylsulfone) oligomers are those of the above formula II wherein each Z' is 2,2-propylidine, i.e., the oligomers of the formula ##STR2## wherein n has the previously stated meaning. Such a poly(arylsulfone) oligomer is a known material having a number average molecular weight of about 2100 and a glass transition temperature of about 145° C.

Numerous methods for the production of the oligomers of the above formula (II) are known but perhaps the most common is to react an alkali metal salt of the appropriate bisphenol with a di(chlorophenyl)sulfone provided in a reactant ratio selected so that the bisphenol salt is present in molar excess, preferably in a substantial molar excess. By way of specific example, the disodium salt of 2,2-di(4-hydroxyphenyl)propane, present in molar excess, reacts with di(4-chlorophenyl)sulfone to produce the oligomer of formula (III). Other methods for the production of the oligomers of formula (II) are available in the art.

The blends of the invention are predominately polyketone polymer with a lesser proportion of poly(arylsulfone) oligomer. The precise proportion of the oligomer to be employed is not critical and percentages by weight from about 0.5% by weight to about 35% by weight, based on total blend, of the poly(arylsulfone) oligomer are satisfactory and quantities of from about 5% by weight to about 25% by weight are preferred.

The method of producing the blends of the polyketone polymer and the poly(arylsulfone) oligomer is not material so long as an intimate blend of the two components is obtained without undue degradation of the components or the resulting blend. Because of the relatively high melting point of the polyketone polymer, blending at an elevated temperature is usually required. A particularly useful procedure is to initimately mix the blend components in the form of granules and/or powder in a high shear mixer. "Intimately mixing" means to mix the components with sufficient mechanical shear and thermal energy to assure that the components of the blend will not delaminate upon processing. Intimate mixing is typically achieved by employing high shear extrusion compounding machines such as twin screw compounding extruders and thermoplastic extruders.

The blends of the polyketone polymer and the poly(arylsulfone) oligomers are usually non-miscible blends and are expected to have properties improved over the polyketone polymer alone. The poly(arylsulfone) oligomer exists as a discrete phase within the polyketone matrix. The blends are not, of course, homogeneous but good blends are obtained when the poly(arylsulfone) polymer is uniformly distributed through the polyketone matrix.

The blends of the invention may also include conventional additives such as antioxidants and stabilizers, fillers and fire resistant materials, mold release agents, pigments and other materials which are designed to increase the processability of the polymer or improve the properties of the resulting blend. Such additives are added by conventional methods prior to, together with or subsequent to the blending of the polyketone polymer and the poly(arylsulfone) oligomer.

The blends of the invention show an improved processability as compared with the unblended polyketone polymer or as compared with blends of higher molecular weight poly(arylsulfone). Thus, for example, a reduced pressure will be sufficient to cause the extrusion of a blend of the invention as compared with the unblended polymer, or the blend is processed at a higher speed by an extruder operating at constant force. The blends are suitable for the production of sheets employed in the packaging industry and for containers for food and drink and parts and housings for the automotive industry. The blends are processed by procedures conventional for thermoplastics including extrusion, injection molding and thermoforming.

The invention is further illustrated by the following Illustrative Embodiments which should not be construed as limiting the invention.

ILLUSTRATIVE EMBODIMENT I

A terpolymer of carbon monoxide, ethylene and propylene was produced employing a catalyst composition formed from palladium acetate, p-toluenesulfonic acid and bis-di(2-methoxyphenyl)phosphino propane. The terpolymer had a melting point of 220° C. and an LVN, measured at 60° C. in m-cresol, of 1.8 dl/g.

ILLUSTRATIVE EMBODIMENT II

A poly(arylsulfone) oligomer was produced by contacting the sodium salt of 2,2-di(4-hydroxyphenyl)propane and di(4-chlorophenyl)sulfone. In a 1 liter flask equipped with a nitrogen inlet, mechanical stirrer, dropping funnel and a Vigrean column, 2,2-di(4-hydroxyphenyl)propane (142.7 g, 0.625 mol), 500 ml of dimethyl sulfoxide, 100 ml of toluene and potassium hydroxide (70.13 g, 1.25 mol) in 70 ml of water were added. The flask and contents were heated to 130°-140° C. to remove water by azeotropic distillation. When the rate of distillation slowed, the temperature was reduced to below 100° C., 50 ml of toluene was added and the distillation resumed. This procedure was repeated 3 times and the temperature of the mixture was raised to 150°-155° C. for 1 hour. Heating was discontinued and when the temperature of the mixture fell to 40°-50° C., di(4-chlorophenyl)sulfone (143.55 G, 0.5 mole) was added. The reaction temperature was raised rapidly to 145° C. and maintained for 6 hours, then raised to 165° C. and maintained for 0.5 hr. After cooling to room temperature, the product mixture was poured slowly into 2 liters of water containing 80 g of oxalic acid. The oligomer was kept in the acid solution for 10 hours and then filtered and washed with distilled water. The oligomeric product (24.5 g, 98% yield) melted at 145°-160° C. and was an off-white powder containing no chlorine.

ILLUSTRATIVE EMBODIMENT III

The following Illustrative Embodiment is based on theoretical considerations. A desired blend would likely comprise 80% weight of the terpolymer of Illustrative Embodiment I and 20% weight of the oligomer of Illustrative Embodiment II. The mixture could be mixed easily as a refluxing melt at a temperature of 250°-260° C. whereas blends with polymeric polyarylsulfone require processing temperatures of at least 290° C. and do not produce refluxing melts.

    ______________________________________                                         Estimated Viscosity Data @ 260° C.                                               Polymeric            Complex Viscosity                                Polyketone                                                                              Arylsulfone                                                                               Oligomer  1 rad/sec pa-sec                                 ______________________________________                                         100      --         --        1000                                             80       20         --        4000                                             80       --         20        1000                                             ______________________________________                                     

What is claimed is:
 1. A composition comprising a non-miscible blend of a major portion of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon and a minor portion of a poly(arylsulfone) oligomer.
 2. The composition of claim 1 wherein the linear alternating polymer is represented by the formula

    --CO--CH.sub.2 --CH.sub.2)].sub.x [CO--B)].sub.y

where B is the moiety of an ethylenically unsaturated hydrocarbon of at least 3 carbon atoms and the ratio of y:x is no more than about 0.5.
 3. The composition of claim 2 wherein the oligomer is represented by the formula ##STR3## wherein Z independently represents a direct carbon-carbon bond or Z is oxygen, sulfur or 2,2-propylidine, and n is an average number of from about 3 to about 20 inclusive.
 4. The composition of claim 3 wherein the oligomer is present in an amount of from about 0.5% by weight to about 35% by weight, based on total blend.
 5. The composition of claim 4 wherein y is
 0. 6. The composition of claim 5 wherein Z is propylidine.
 7. The composition of claim 4 wherein B is a moiety of propylene and the ratio of y:x is from about 0.01 to about 0.1.
 8. The composition of claim 7 wherein Z is propylidine.
 9. The composition of claim 8 wherein the oligomer is present in an amount of from about 5% by weight to about 25% by weight, based on total blend. 